Air handler apparatuses for evaporative fluid cooling and methods thereof

ABSTRACT

An air handler apparatus includes at least one heat exchanger device with a cooling fluid region separated from a temperature transfer fluid region, an evaporator device comprising an evaporator housing and at least one evaporator coil, and a pump. The cooling fluid region has a cooling fluid input and a cooling fluid output and the temperature transfer fluid region has a temperature transfer fluid input and a temperature transfer fluid output. The evaporator housing defines an air passage having an air input and an air output. The evaporator coil has an evaporator coil input coupled to the temperature transfer fluid output and an evaporator output coupled to temperature transfer fluid input of the temperature transfer fluid region in the heat exchanger device. The pump is coupled to the temperature transfer fluid region in the heat exchanger device to pump temperature transfer fluid between the temperature transfer fluid region and the evaporator coil when activated.

This application is a continuation-in-part of prior U.S. patentapplication Ser. No. 14/997,057, filed Jan. 15, 2016, which is herebyincorporated by reference in its entirety.

FIELD

This technology relates to air handler apparatuses for evaporative fluidcooling and methods thereof.

BACKGROUND

Currently, prior cooling systems in most commercial and data centeroperations operate with standard flow rates for water as high as over300 gallons per minute (GPM). Unfortunately, moving this water throughthese prior cooling systems at these high flow rates does not allow forthe absorption of much heat by each gallon of water resulting in only asmall difference between the temperature of the water entering andleaving these prior cooling systems resulting in low delta T syndrome.Typically, with low delta T syndrome the flow rate or gallons per minuteis high and the temperature difference is low between about ten totwelve degrees and in reality often between about two and ten degrees.As a result of these design issues, these prior cooling systems oftenwork acceptably, but require very significant amounts of energy andmaintenance.

To address this issue, prior solutions have tried various combinationsof increasing the flow and/or adding more cooling towers. Unfortunately,increasing the flow may again have a negative impact on the amount oftemperature drop or delta T which is attainable and thus is not a viablesolution. Further, the addition of more cooling towers, related piping,and pumps adds further expense and takes up a greater amount of space,none of which is desirable.

SUMMARY

An air handler apparatus includes at least one heat exchanger devicewith a cooling fluid region separated from a temperature transfer fluidregion, an evaporator device comprising an evaporator housing and atleast one evaporator coil, and a pump. The cooling fluid region has acooling fluid input and a cooling fluid output and the temperaturetransfer fluid region has a temperature transfer fluid input and atemperature transfer fluid output. The evaporator housing defines an airpassage having an air input and an air output. The evaporator coil hasan evaporator coil input coupled to the temperature transfer fluidoutput and an evaporator output coupled to temperature transfer fluidinput of the temperature transfer fluid region in the heat exchangerdevice. The pump is coupled to the temperature transfer fluid region inthe heat exchanger device to pump temperature transfer fluid between thetemperature transfer fluid region and the evaporator coil whenactivated.

A method for making an air handler apparatus includes providing at leastone heat exchanger device with a cooling fluid region separated from atemperature transfer fluid region. The cooling fluid region has acooling fluid input and a cooling fluid output and the temperaturetransfer fluid region has a temperature transfer fluid input and atemperature transfer fluid output. An evaporator device with anevaporator housing and at least one evaporator coil is provided. Theevaporator housing defines an air passage having an air input and an airoutput. The evaporator coil has an evaporator coil input coupled to thetemperature transfer fluid output and an evaporator output coupled totemperature transfer fluid input of the temperature transfer fluidregion in the heat exchanger device. A pump is coupled to thetemperature transfer fluid region in the heat exchanger device to pumptemperature transfer fluid between the temperature transfer fluid regionand the evaporator coil when activated.

This technology provides a number of advantages including providing moreeffective and efficient air handler apparatuses for evaporative fluidcooling and methods. In particular, this technology provides air handlerapparatuses which are able to assist evaporative fluid coolingapparatuses achieve a high delta T and a low flow rate, i.e. gallons perminute (GPM), that are able to easily avoid low delta syndrome. By wayof example, this technology can provide a high delta T of between twentydegrees to forty-five degrees and also a low flow rate or gallons perminute. Additionally, with this high delta T and a low flow rate design,this technology is able to provide a significant reduction, i.e. oftenin excess of 50%, in the size and cost of piping and other parts whencompared against prior cooling systems. Further, with this high delta Tand a low flow rate design, this technology is able to output pure,non-saturated air and is able to utilize sprayer water that is chemicalfree. This technology also allows for a unique phased in integration ofthe compressor chiller that allow that compression chiller to operate ata greatly reduced lift compared to prior designs thereby lowering kW/tonrelationship.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a functional block diagram of an example of an environmentwith an example of an evaporative fluid cooling apparatus with arefrigerant coil;

FIG. 2 is a block diagram of an example of the compressor chillerillustrated in FIG. 1;

FIG. 3 is a block diagram of an example of an evaporative coolermanagement computing device illustrated in FIG. 1;

FIG. 4 is a functional block diagram of an example of operating theevaporative fluid cooling apparatus with the refrigerant coilillustrated in FIG. 1;

FIG. 5 is functional block diagram of an example of another evaporativefluid cooling apparatus with a split fluid coil and housing;

FIG. 6 is functional block diagram of an example of yet anotherevaporative fluid cooling apparatus with a dual split fluid coil andhousing; AND

FIG. 7 is functional block diagram of another example of air handlerapparatus.

DETAILED DESCRIPTION

An environment 10 with an example of an evaporative fluid coolingapparatus 12(1), air handler apparatus 32(1), and heat source 40, suchas a building by way of example only, is illustrated in FIG. 1. In thisparticular example, the evaporative fluid cooling apparatus 12(1)includes a cooling housing 14, at least two fluid coils 16(1)-16(2), anoptional refrigerant coil 18, a sprayer apparatus 20, an air movementapparatus 22, an optional compressor chiller 24, and evaporative coolermanagement computing device 60, although the apparatus could includeother types and numbers of systems, devices, components, and/or otherelements in other configurations, such as those illustrated in FIGS. 5and 6 by way of example only. This technology provides a number ofadvantages including providing more effective and efficient evaporativefluid cooling apparatuses and methods.

The cooling housing 14 has side walls which define a cooling chamber 17having air input 23 and an air output 25 and provides a supportingstructure for the fluid coils 16(1)-16(2), the optional refrigerant coil18, the sprayer apparatus 20, the air movement apparatus 22, theoptional compressor chiller 24, the collection device 37, and theevaporative cooler management computing device 60 of the evaporativefluid cooling apparatus 12(1), although the housing 14 could have otherconfigurations and could provide a supporting structure for other typesand/or numbers of other systems, devices, components, and/or otherelements.

The cooling housing 14 may also optionally include one or morecontrollable vents or louvers 26 along one or more side surfaces of thecooling housing 14, although the housing 14 could provide other typesand/or numbers of adjustable access points. In this particular example,the controllable vents or louvers 26 are each constructed to at leasthave a closed position to seal a corresponding opening in the coolinghousing 14 and an open position which can be managed by the controller.In the open position, the vents or louvers 26 provide a passage to allowthe introduction of fresh, cool and dryer outside air to enter thecooling chamber 17 and pass between one or more of the fluid coils16(1)-16(2) and/or the optional refrigerant coil 18 to increase the freecooling effects, further reducing the need to engage and also thepossible load on the compressor chiller 24 when engaged.

Each of the controllable vents or louvers 26 may have a controllercomprising a processor, a memory, a communication interface which arecoupled together by a bus or other communication link, although othertypes and/or numbers of other systems, device, components, and/or otherelements in other configurations could be used and/or other approachesfor managing the operation of the controllable vents or louvers 26 maybe used. Each of the controllers in the controllable vents or louvers 26may be coupled to receive, respond to and/or execute instructions fromthe evaporative cooler management computing device 60 to move thecontrollable vents or louvers 26 between open and closed positions usingone or more electromechanical control devices, although the operation ofthe controllable vents or louvers 26 may be managed in other manners,such as manually by way of example only, and may be configured toperform other types and/or numbers of other operations.

The fluid coils 16(1)-16(2) each comprise heat transfer working fluidconduits with one of the fluid coils 16(1) having an input that isconfigured to be coupled to a return of cooling fluid, an output of thefluid coil 16(1) is coupled to an input of the fluid coil 16(2),although other types and/or numbers of fluid coils in otherconfigurations may be used. The fluid coil 16(1) which receives theinitial return of the heated fluid from the air handler apparatus 32(1)is located in the cooling housing 14 adjacent the air output 25. Thefluid coil 16(2) which receives the fluid from the fluid coil 16(1) islocated adjacent the air inputs 23 in the cooling housing 14.Accordingly, with this configuration to receive fluid in the fluid coil16(1) adjacent the air output 25 of the cooling housing 14 and then tofurther cool and return fluid to the fluid coil 16(2) adjacent the airinput 23 of the cooling housing 14 is in an inverse with respect to theabsorption of heat from the fluid in the fluid coils 16(1)-16(2) in thecooling housing 14 based on a direction of air flow from the one or moreair inputs 23 to the air output 25. As a result, with this configurationheated fluid from the air handler apparatus 32(1) may now be transportedto the fluid coils 16(1)-16(2) in the evaporative fluid coolingapparatus 12(1) at lower volumes than possible with prior designsbecause the heated fluid carries more heat energy per unit volume.

In particular, with this example when the heated fluid enters the fluidcoil 16(1) adjacent the air output 25 of the cooling housing 14, theheated fluid in the fluid coil 16(1) will be exposed to cool wet airthat has already been cooled and supersaturated by the second coil 16(2)adjacent the air inputs 23 and through evaporative cooling of spraywater from the sprayer apparatus 20 to nearly the wet bulb temperaturein the atmosphere. When the cool wet air hits the fluid coil 16(1), itabsorbs heat, and by the time it exits the cooling housing 14 at the airoutput 25, it is at or warm enough that it has more than enough spacefor the water it has absorbed and also eliminates plumes. At the sametime the fluid in the fluid coil 16(1) is cooled, so that by the time itenters the fluid coil 16(2) less cooling is required to reach nearly thewet bulb temperature. As a result, this example of the technologyessentially provides free cooling all the way up to a wet bulb of about60 degrees Fahrenheit or an ambient temperature of about 80 degreeswithout needing to engage the compressor chiller 24 and also providesother benefits, such as substantial savings in energy, a high delta Tand a low required flow rate for the fluid from the air handlerapparatus 32(1) by way of example.

An example of the benefits of this high delta T and low flow rate designwith this technology resulting in reduced requirements for the fluidcoils 16(1)-16(2) and related piping is set forth below. Again as notedearlier, this technology is able to utilize a high delta T of betweentwenty degrees to forty-five degrees and also a low flow rate or gallonsper minute. Additionally, the formula for calculating a ton is(GPM×8.33)×Delta T=BTU. Accordingly, assuming a delta T of thirty fivedegrees, an example of the decrease in flow requirements is set forthbelow:(100 GPM×8.33)×10=8,330 BTU(50 GPM×8.33)×35=14,577 BTU

As illustrated above, the lower GPM with the higher delta T, e.g.thirty-five degrees in this example, in accordance with an example ofthis technology when compared against a prior cooling system with a lowdelta T of ten which is typical for prior systems has the higher BTU.Accordingly, by using this technology a significant reduction in sizeand cost, i.e. purchase and installation, as well as a reduction intonnage demands on the chiller can be achieved.

A fluid pump 35 may be coupled to the piping to the fluid coil 16(1),although the fluid pump may be in other locations and other types and/ornumbers of fluid movement devices maybe used. The fluid pump 35 may havea controller comprising a processor, a memory, a communication interfacewhich are coupled together by a bus or other communication link,although other types and/or numbers of other systems, device,components, and/or other elements in other configurations could be usedand/or other approaches for managing the operation of the fluid pump 34may be used. The controller in the fluid pump 35 may be coupled toreceive, respond to and/or execute instructions from the evaporativecooler management computing device 60 to manage the engagement of andrate of pumping of the cooling fluid through the loop from the fluidcoils 16(1)-16(2) and out to the air handler apparatus 32(1) and back,although the operation of the fluid pump 35 may be managed in othermanners, such as manually by way of example only and may be configuredto perform other types and/or numbers of other operations.

With this low flow rate design, this technology is able to utilize amuch smaller, less expensive, and more energy efficient fluid pump 35than possible with prior evaporative cooling system. Additionally, withthis low flow rate design this technology is able to use much thinnerfluid coils 16(1)-16(2) and connecting pipes than prior coolingevaporative fluid cooling systems which provides a significant reductionin size and cost. Further, the ability to use much thinner fluid coils16(1)-16(2) with this technology when compared to prior cooling systemsenables air to more easily flow from the air inputs 23 through the fluidcoils 16(1)-16(2) in the cooling chamber 17 to the air output 25reducing the size and required power for the air movement apparatus 22.

The optional refrigerant coil 18 comprises another heat transfer conduitand has an input that is configured to be coupled to a return from arefrigerant system 30 and an output that is configured to be coupled toa supply from the refrigerant system 30, although other types and/ornumbers of refrigerant coils coupled to other types and/or numbers ofsources could be used. In this particular example, the refrigerantsystem 30 is positioned in the air handler apparatus 32(1) to remove asignificant amount of heat prior to the air reaching a heat exchangerdevice 28(1) in the air handler apparatus 32(1), to provide additionalcooling.

A refrigerant pump 34 may be coupled to the piping between the optionalrefrigerant coil 18 and the refrigerant system 30, although therefrigerant pump 34 may be in other locations and other types and/ornumbers of fluid movement devices maybe used. In this particularexample, the refrigerant pump 34 is a frictionless magnetic bearingstype pump which as result is oil free and thus more efficient and lowermaintenance, although other types of pumps could be used, such as a pumpwith sealed bearings unit that does not require oil in the refrigerant.Using an oil free refrigerant pump 34 provides advantages because oil isan insulator and as result does not take heat, but does take up volumewhich greatly reducing the efficiency of the refrigerant fluid,increasing efficiency by up to 20%.

The refrigerant pump 34 may have a controller comprising a processor, amemory, a communication interface which are coupled together by a bus orother communication link, although other types and/or numbers of othersystems, device, components, and/or other elements in otherconfigurations could be used and/or other approaches for managing theoperation of the refrigerant pump 34 may be used. The controller in therefrigerant pump 34 may be coupled to receive, respond to and/or executeinstructions from the evaporative cooler management computing device 60to manage the engagement of and rate of pumping of the refrigerant fluidthrough the loop from between the optional refrigerant coil 18 and therefrigerant system 30, although the operation of the refrigerant pump 34may be managed in other manners, such as manually by way of example onlyand may be configured to perform other types and/or numbers of otheroperations.

The sprayer apparatus 20 may include a sprayer pump 36 with acontroller, piping, and a plurality of nozzles oriented to spray afluid, such as water by way of example only, on and positioned above thefluid coil 16(2) and below the optional refrigerant coil 18 and thefluid coil 16(2) to cool the air in the cooling chamber 17 viaevaporative cooling, although the sprayer apparatus 20 could bepositioned in other locations and/or to spray on other devices, such asthe fluid coil 16(1) by way of example only. Any non-evaporated water orother fluid that was sprayed drips down into a collection device 37 andmay be pumped by the sprayer pump 36 back to the nozzles untilevaporated.

The sprayer pump 36 may have a controller comprising a processor, amemory, a communication interface which are coupled together by a bus orother communication link, although other types and/or numbers of othersystems, device, components, and/or other elements in otherconfigurations could be used and/or other approaches for managing theoperation of the sprayer pump 36 may be used. The controller in thesprayer pump 36 may be coupled to receive, respond to and/or executeinstructions from the evaporative cooler management computing device 60to manage the engagement of and rate of pumping of the spray fluidthrough the loop from between the sprayer apparatus 20 and thecollection device 37, although the operation of the sprayer pump 36 maybe managed in other manners, such as manually by way of example only andmay be configured to perform other types and/or numbers of otheroperations.

The air movement apparatus 22, such as a fan by way of example only, isconnected at the top of the cooling housing 14 and when activatedgenerates a flow of air through the cooling chamber 17 from the one ormore air inputs 23 through the cooling chamber 17 and out the air output25, although other types and/or numbers of air movement apparatuses inother locations could be used. The air movement apparatus 22 may have acontroller comprising a processor, a memory, a communication interfacewhich are coupled together by a bus or other communication link,although other types and/or numbers of other systems, device,components, and/or other elements in other configurations could be usedand/or other approaches for managing the operation of the sprayer pump36 may be used. The controller in the air movement apparatus 22 may becoupled to receive, respond to and/or execute instructions from theevaporative cooler management computing device 60 to manage theengagement of and rate air flow from the one or more air inputs 23through the cooling chamber 17 and out the air output 25, although theoperation of the air movement apparatus 22 may be managed in othermanners, such as manually by way of example only and may be configuredto perform other types and/or numbers of other operations.

Referring to FIGS. 1 and 2, the optional compressor chiller 24 has afirst compressor chiller input coupled to an output of the fluid coil16(1), a second compressor chiller input coupled to an output of thefluid coil 16(2), a first compressor chiller output coupled to the inputof the fluid coil 16(1), and a second compressor chiller outputconfigured to be coupled to the fluid supply to the one or more airhandler device 32. The compressor chiller 24 is a physical compressor 50that compresses a refrigerant fluid to allow it to create cold in anevaporator 52, the heat removed from the cooling fluid, such as water byway of example, into the refrigerant fluid is transferred back into thecooling fluid returning back to the input of the fluid coil 16(1) viathe condenser 54. During warmer weather, such as a temperature above awet bulb of about 60 degrees Fahrenheit or an ambient temperature ofabout 80 degrees, the compressor 50 in the compressor chiller 24 mountedbelow or next to the cooling housing 14 may be engaged to remove apercentage of the cooling fluid from the output of the fluid coil 16(2),uses compressed refrigerant fluid to cool some of that cooling fluid inorder to cool a percentage of that cooling fluid, and then combines itwith the other cooling fluid from the output of the fluid coil 16(2) forreturn to the heat exchange device 28(1) in air handler apparatus 32(1)so as to effectively deliver the desired temperature of return coolingfluid. Meanwhile, the heat removed by the refrigerant fluid is movedinto the remaining cooling fluid taken and, as noted above, is routedback to the input to the fluid coil 16(1) of the cooling housing 14 tocombine with the heated cooling fluid coming back from the air handlerapparatus 32(1) for heat rejection.

The optional compressor chiller 24 may have a controller comprising aprocessor, a memory, a communication interface which are coupledtogether by a bus or other communication link, although other typesand/or numbers of other systems, device, components, and/or otherelements in other configurations could be used and/or other approachesfor managing the operation of the optional compressor chiller 24 may beused. The controller in the optional compressor chiller 24 may becoupled to receive, respond to and/or execute instructions from theevaporative cooler management computing device 60 to manage theengagement of and rate of operation of the optional compressor chiller24, although the operation of the optional compressor chiller 24 may bemanaged in other manners, such as manually by way of example only andmay be configured to perform other types and/or numbers of otheroperations.

A first coil diverter valve apparatus 38(1) may be adjusted to divertthe flow of the cooling fluid and has a first coil diverter valve inputcoupled to an output of the fluid coil 16(1), a first coil divertervalve output coupled to an input to the fluid coil 16(2), and a secondcoil diverter valve output coupled to an input to the optionalcompressor chiller 24, although other manners for diverting the flow ofthe cooling fluid can be used. A second coil diverter valve apparatusvalve 38(2) has a first second coil diverter valve input coupled to theoutput of the fluid coil 16(2), a first coil diverter valve outputcoupled to an input of the optional compressor chiller 24, and a secondcoil diverter valve output configured to be coupled to the fluid supplyto the air handler apparatus device 32. In this example, first coildiverter valve apparatus 38(1) and the second coil diverter valveapparatus valve 38(2) are uniquely positioned inside this example of thedesign to allow the compressor chiller 24 to operate at a much lowerlift than possible with prior designs therefore lowering kw\ton even inextreme atmosphere conditions.

Each of the first coil diverter valve apparatus 38(1) and the secondcoil diverter valve apparatus valve 38(2) may have a controllercomprising a processor, a memory, a communication interface which arecoupled together by a bus or other communication link, although othertypes and/or numbers of other systems, device, components, and/or otherelements in other configurations could be used and/or other approachesfor managing the operation of the first coil diverter valve apparatus38(1) and the second coil diverter valve apparatus valve 38(2) may beused. Each of the controllers in the first coil diverter valve apparatus38(1) and the second coil diverter valve apparatus valve 38(2) may becoupled to receive, respond to and/or execute instructions from theevaporative cooler management computing device 60 to move the first coildiverter valve apparatus 38(1) and the second coil diverter valveapparatus valve 38(2) between open and closed positions using one ormore electromechanical control devices to control an amount of thecooling fluid which is diverted, although the operation of the firstcoil diverter valve apparatus 38(1) and/or the second coil divertervalve apparatus valve 38(2) may be managed in other manners, such asmanually by way of example only, and may be configured perform othertypes and/or numbers of operations

The evaporative cooler management computing device 60 includes aprocessor 62, a memory 64, and a communication interface 66 which arecoupled together by a bus 68 or other communication link, although theevaporative cooler management computing device 60 may include othertypes and/or numbers of elements in other configurations.

The processor 62 of the evaporative cooler management computing device60 may execute one or more computer-executable instructions stored inthe memory 64 for the methods illustrated and described with referenceto the examples herein, although the processor can execute other typesand/or numbers of programmed instructions and may be configured to becapable of performing other types and/or numbers of operations. Theprocessor 60 in the evaporative cooler management computing device 60may comprise one or more central processing units (“CPUs”) or generalpurpose processors with one or more processing cores, although othertypes of processor(s) could be used.

The memory 64 of the evaporative cooler management computing device 60stores these programmed instructions for one or more aspects of thepresent technology as described and illustrated by way of the examplesherein, although some or all of the programmed instructions could bestored and executed elsewhere. A variety of different types of memorystorage devices, such as random access memory (RAM), read only memory(ROM), hard disk drives, solid state drives, or other computer readablemedia which is read from and written to by a magnetic, optical, or otherreading and writing system that is coupled to the processor 62, can beused for the memory 64.

The communication interface 66 operatively couples and communicatesbetween the evaporative cooler management computing device 60 and acontroller for each of the air movement apparatus 22, the compressorchiller 24, the controllable vents 26, the refrigerant pump 34, thefluid pump 35, and the coil diverter valve apparatuses 38(1) and 38(2)which are all coupled together by one or more communication networks,although other types and/or numbers of communication networks or systemswith other types and numbers of connections and configurations to otherdevices and elements. By way of example only, the one or morecommunication networks can use TCP/IP over Ethernet andindustry-standard protocols, including NFS, CIFS, SOAP, XML, LDAP, andSNMP, although other types and numbers of communication networks, can beused.

In this example, an air handler apparatus 32(1) with one or more heatexchangers 28(1) may have an optional dampening device 70 coupled to aninput from a cooling loop with a heat source 40, such as a building byway of example only, and another cooling loop with the evaporative fluidcooling apparatus 12(1), although the evaporative fluid coolingapparatus 12(1) could be coupled to other types and/or numbers of othersystems in other manners. If the air handler apparatus 32(1) has morethan one heat exchanger, the heat exchanger device 28(1) adjacent theinput to the air handler apparatus 32(1) may use a refrigerant fluidwith a different boiling point than another heat exchanger device 28(1)near an output from the air handler apparatus 32(1). The optionaldampening device 70 may have a controller comprising a processor, amemory, a communication interface which are coupled together by a bus orother communication link, although other types and/or numbers of othersystems, device, components, and/or other elements in otherconfigurations could be used and/or other approaches for managing theoperation of the dampening device 70 may be used. The controller in theoptional dampening device 70 may be coupled to receive, respond toand/or execute instructions from the evaporative cooler managementcomputing device 60 to manage and optimize operation of the dampeningdevice 70, although the operation of the optional compressor chiller 24may be managed in other manners, such as manually by way of example onlyand may be configured to perform other types and/or numbers of otheroperations. The air handler apparatus 32(1) may also have therefrigerant system 30 in the return air flow from the heat source 40,although the air handler apparatus may have other types and/or numbersof other systems, devices, components and/or other elements in otherconfigurations.

The evaporative cooler management computing device 60 may be coupled tosend, respond to and/or execute one or more programmed instructions formanaging the operation of one or more of the controllers for the airmovement apparatus 22, the optional compressor chiller 24, thecontrollable vents or louvers 26, the refrigerant pump 34, the fluidpump 35, the sprayer pump 36, and the first coil diverter valveapparatus 38(1) and the second coil diverter valve apparatus valve 38(2)to react to the changing environment and changing load requirements ofthe heat source 40, such as a building by way of example only, and thesecontrols may be based on input data and/or based on one or morecharacteristics, such as current outside temperature or current fluidtemperature by way of example only. As the outdoor temperatureincreases, the evaporative cooler management computing device 60 mayhave programmed instructions to automatically increase fan speed of theair movement apparatus 22, then to start the sprayer pump 36, and thenadjust the rate of cooling fluid to the compressor chiller 24 and engagethe operation of the compressor chiller 24 in small increments, and onlyto the point necessary to achieve the desired exiting cooling fluidtemperature. The evaporative cooler management computing device 60 mayalso have programmed instructions to adjust the opening of thecontrollable vents or louvers 26, the engagement of and rate ofrefrigerant pumped by the refrigerant pump 34, and/or the rate ofcooling fluid being pumped fluid pump 35 to achieve the desired exitingcooling fluid temperature. Since the evaporative cooler managementcomputing device 60 may be located in the same unit as the fluid coils16(1)-16(2) and/or and the chiller compressor 24 which may be in oroutside the cooling chamber 17, it will instantly react to changesduring the day, may have programmed instructions and prior storedoperation data to predict the needs in the near future and adapt to eachvariable as they change to operate the unit in the most efficient waypossible.

Although the exemplary environment 10 with evaporative fluid coolingapparatus 12(1) which has the evaporative cooler management computingdevice 60 and the controllers for the air movement apparatus 22, theoptional compressor chiller 24, the controllable vents or louvers 26,the refrigerant pump 34, the fluid pump 35, the sprayer pump 36, and thefirst coil diverter valve apparatus 38(1) and the second coil divertervalve apparatus valve 38(2) are described and illustrated herein, othertypes and numbers of systems, devices, components, and/or elements inother topologies can be used. It is to be understood that the systems ofthe examples described herein are for exemplary purposes, as manyvariations of the specific hardware and software used to implement theexamples are possible, as will be appreciated by those skilled in therelevant art(s).

In addition, two or more computing systems or devices can be substitutedfor any one of the systems or devices in any example. Accordingly,principles and advantages of distributed processing, such as redundancyand replication also can be implemented, as desired, to increase therobustness and performance of the devices and systems of the examples.The examples may also be implemented on computer system(s) that extendacross any suitable network using any suitable interface mechanisms andtraffic technologies, including by way of example only teletraffic inany suitable form (e.g., voice and modem), wireless traffic media,wireless traffic networks, cellular traffic networks, G3 trafficnetworks, Public Switched Telephone Network (PSTNs), Packet DataNetworks (PDNs), the Internet, intranets, and combinations thereof.

The examples may also be embodied as one or more non-transitory computerreadable media having instructions stored thereon for one or moreaspects of the present technology as described and illustrated by way ofthe examples herein, as described herein, which when executed by aprocessor, cause the processor to carry out the steps necessary toimplement the methods of the examples, as described and illustratedherein.

An example of a method for using an evaporative cooler apparatus 12(1)will now be described with reference to FIGS. 1-4. In this particularexample, the optional dampening device 70 may be adjusted by theevaporative cooler management computing device 60 based on at least onecharacteristic, such as outside air temperature by way of example only,to provide the appropriate mix of outside air with returning air fromthe heat source 40, such as a building by way of example only, to theair handler apparatus 32(1), although other manner for managing the airsupplied to the air handler apparatus 32(1) can be used. Meanwhile,cooling fluid in the heat exchanger device 28(1) in the air handlerapparatus 32(1) is continuously managed by the evaporative coolerapparatus 12(1) to ensure maximum heat absorption at exit from the heatexchanger device 28(1) back to the heat source 40.

To manage this cooling fluid, a fluid pump 35 in the evaporative coolerapparatus 12(1) when activated and the rate of operation is controlledby the evaporative cooler management computing device 60 based on atleast one characteristic, such as desired temperature by way of exampleonly, pumps the cooling fluid in the pipes through the fluid coil 16(1)adjacent the air output 25 in the cooling chamber 17 and then throughthe fluid coil 16(2) adjacent the one or more air inputs 23 in thecooling chamber 17, although other types and/or numbers of fluidmovement devices in other locations may be used. Accordingly asdiscussed earlier, this configuration to receive fluid in the fluid coil16(1) adjacent the air output 25 of the cooling housing 14 and then tofurther cool and return fluid to the fluid coil 16(2) adjacent the airinput 23 of the cooling housing 14 is in an inverse with respect to theabsorption of heat from the fluid in the fluid coils 16(1)-16(2) in thecooling housing 14 based on a direction of air flow from the one or moreair inputs 23 to the air output 25. As a result, with this configurationheated fluid from the air handler apparatus 32(1) may now be transportedto the fluid coils 16(1)-16(2) in the evaporative fluid coolingapparatus 12(1) at lower volumes than possible with prior designsbecause the heated fluid carries more heat energy per unit volume.

In this particular example, when activated, cooling fluid, such ascooling fluid having a flow rate of 100 GPM and a temperature of 88degrees in this example, containing heat from the heat exchangers 28(1)air handler apparatus 32(1) is received. This cooling fluid may becombined with heated cooling fluid from the optional compressor chiller24, when activated and managed by the evaporative cooler managementcomputing device 60 based on at least one characteristic, such as fluidtemperature by way of example only, via one of the outputs from thesecond coil diverter valve apparatus valve 38(2) also activated andmanaged by the evaporative cooler management computing device 60, toprovide in this example cooling fluid having a flow rate of 133 GPM at atemperature of 94 degrees to an input of the fluid coil 16(1). Thiscooling fluid having a flow rate of 133 GPM at a temperature of 94degrees enters the fluid coil 16(1) in the cooling chamber 17 adjacentthe air output 25 and transfers as much heat energy in the cooling fluidas possible to the atmosphere and then exits as cooling fluid having aflow rate of 133 GPM at a temperature of 84 degrees in this example viaan output from the fluid coil 16(1). Accordingly, in this examplethrough reheating cooled air coming up the cooling chamber 17 from thefluid coil 16(2), the cooling fluid in fluid coil 16(1) is precooled forthe fluid coil 16(2).

In this example, this cooling fluid descends to an input of the firstcoil diverter valve apparatus valve 38(1) activated and managed by theevaporative cooler management computing device 60 and which has a firstoutput to divert an adjustable portion of the cooling fluid, in thisexample cooling fluid having a flow rate of 100 GPM at a temperature of84 degrees, to an input of the fluid coil 16(2) adjacent air inputs 23in the cooling chamber 17 and a second output to divert an adjustableportion of the cooling fluid, in this example cooling fluid having aflow rate of 33 GPM at a temperature of 84 degrees, to the optionalcompressor chiller 24. In this example, until a wet bulb of about 60degrees Fahrenheit or an ambient temperature of about 80 degrees isreached, the first coil diverter valve apparatus valve 38(1) would notdivert any cooling fluid to the compressor chiller 24, although thediversion of cooling fluid to the compressor chiller 24 by the firstcoil diverter valve apparatus valve 38(1) can be at other storedtemperatures.

The precooled cooling fluid enters the fluid coil 16(2) which transfersas much heat energy as possible in the cooling fluid to the atmospherein the cooling chamber 17. Spray water from the sprayer apparatus 20 ata rate adjusted and managed by the evaporative cooler managementcomputing device 60 assists with this heat transfer throughvaporization. The cooling fluid then exits the fluid coil 16(2) in thisexample as cooling fluid having a flow rate of at 100 GPM at atemperature of 74 degrees, via an output from the fluid coil 16(2) to aninput of the second coil diverter valve apparatus valve 38(2). Theoperation of how much if any cooling fluid is diverted by the secondcoil diverter valve apparatus valve 38(2) is managed by the evaporativecooler management computing device 60 based on at least onecharacteristic, such as one or more temperature readings by way ofexample only. Again, in this example until a wet bulb of about 60degrees Fahrenheit or an ambient temperature of about 80 degrees isreached, the second coil diverter valve apparatus valve 38(1) would notdivert any cooling fluid to the compressor chiller 24, although thediversion of cooling fluid to the compressor chiller 24 by the firstcoil diverter valve apparatus valve 38(1) can be at other storedtemperatures. In this particular example, the second coil diverter valveapparatus valve 38(2) has a first output that is configured to providecooling fluid having a flow rate of 67 GPM at a temperature of 74degrees is diverted to the piping towards the heat exchanger device28(1) and a second output is coupled to provide another adjustableportion of this cooling fluid, in this particular example cooling fluidhaving a flow rate of 33 GPM at a temperature of 74 degrees to thecompressor chiller 24.

Accordingly, in this example as described above when the heated coolingfluid enters the fluid coil 16(1) adjacent the air output 25 of thecooling housing 14, the heated cooling fluid in the fluid coil 16(1)will be exposed to cool wet air that has already been cooled andsupersaturated by the second coil 16(2) adjacent the air inputs 23 andthrough evaporative cooling of spray water from the sprayer apparatus 20at a rate adjusted and managed by the evaporative cooler managementcomputing device 60 to nearly the wet bulb temperature in theatmosphere. When the cool wet air hits the fluid coil 16(1) byactivation and management of the rate of operation of the air movementdevice 22 by the evaporative cooler management computing device 60 basedon at least one characteristic, such as outside air temperature by wayof example only, to provide and manage an air flow rate from the one ormore air inputs 23 to the air output 25, the flowing air in the coolingchamber 17 absorbs heat, and by the time it exits the cooling housing 14at the air output 25, it is at or warm enough that it has more thanenough space for the water it has absorbed and also eliminates plumes.By the time the cooling fluid in the fluid coil 16(1) enters the fluidcoil 16(2), less cooling is required to reach nearly the wet bulbtemperature. As a result, this example of the technology essentiallyprovides free cooling all the way up to a wet bulb of about 60 degreesFahrenheit or an ambient temperature of about 80 degrees without needingto engage the compressor chiller 24 and also provides other benefits,such as substantial savings in energy, a high delta T and a low requiredflow rate for the fluid from the air handler apparatus 32(1) by way ofexample. The optional vents or louvers 26 may also be activated andmanaged by the evaporative cooler management computing device 60 basedon at least one characteristic, such as outside air temperature by wayof example only, to be adjusted to different open positions to provideadditional air flow into the cooling chamber 17

In this example, above the temperatures noted above, the optionalcompressor chiller 24 may be activated and managed by the evaporativecooler management computing device 60 to cool an adjustable portion ofthe received cooling fluid based on at least one characteristic, such asfluid temperature by way of example only. In particular, in this examplecooling fluid having a flow rate of 33 GPM at a temperature of 62degrees, and which is then combined with the cooling fluid having a flowrate of 67 GPM at a temperature of 74 degrees. This cooling fluid havinga flow rate of 100 GPM at a temperature of 70 degrees is then providedto the supply to the air handler apparatus 32(1). Additionally, theother adjustable portion of the received cooling fluid, in thisparticular example cooling fluid having a flow rate of 33 GPM at atemperature of 96 degrees, which is being used to transfer the extractedheat from the other cooling fluid in the compressor chiller 24 justdescribed above, is provided back to the input to the fluid coil 16(1)as described earlier.

Additionally, the evaporative fluid cooling apparatus 12(1) may haverefrigerant fluid that enters an input of the optional refrigerant coil18 when a refrigerant pump 34 is activated and managed by theevaporative cooler management computing device 60 and transfers as muchheat energy in the refrigerant fluid as possible to the atmosphere andthen exits via an output to refrigerant system 30 integrated with theair handler apparatus 32(1) in the building 40 to complete the loop.

Referring to FIG. 5, an example of another evaporative fluid coolingapparatus 12(2) is illustrated. The evaporative fluid cooling apparatus12(2) is the same in structure and operation as the evaporative fluidcooling apparatus 12(1), except as illustrated and described herein.Elements in the evaporative fluid cooling apparatus 12(2) which are likethose in evaporative fluid cooling apparatus 12(1) have like referencenumerals.

In this example, the housing 14 in the evaporative fluid coolingapparatus 12(2) includes a moveable barrier 100 which may be adjustablypositioned in the housing 14 to divide a portion of the cooling chamber17 into two separate regions which permit air flow between the air input23 and the air output 25, although the cooling chamber 17 can be dividedin other manners and other proportions. The fluid coil 16(1) in theevaporative fluid cooling apparatus 12(2) comprises two separate fluidcoils 16(1 a) and 16(1 b) which are coupled in series with each of thefluid 16(1 a) and 16(1 b) positioned to extend across at least a portionof one of the regions in the cooling chamber 17, although the fluid coil16(1) may comprises other numbers of fluid coils in otherconfigurations. The air movement device 22 comprises two separate airmovement device 22(a) and 22(b) which are each positioned adjacent theair output 25 in one of the regions in the cooling chamber 17, althoughthe air movement device 22 may comprises other numbers of air movementdevices in other configurations and locations. The two separate airmovement device 22(a) and 22(b) may each be controlled separately by theevaporative cooler computing device 60 to generate a flow of air throughthe cooling chamber 17 from the one or more air inputs 23 through thecooling chamber 17 and out the air output 25, although the air movementdevice 22(a) and 22(b) may each be controlled in other manners. One ofthe controllable vents or louvers 26 is positioned in the housing 14 toprovide controlled access to one of the regions in the cooling chamber17, although other types and/or numbers of controllable vents or louvrescould be used. The sprayer apparatus 20 in the evaporative fluid coolingapparatus 12(2) may be controlled by the evaporative cooler computingdevice 60 based on at least one characteristic, such as outside airtemperature by way of example only, to spray in only one of the regionsin the cooling chamber 17 on the outlet side to supply the cooled fluidback to heat exchanger device 28(1) in the air handler apparatus 32(1),although the sprayer apparatus 20 could be configured to spray in theregions in the cooling chamber 17 in other manners and/or patterns.

As noted earlier, the operation of the evaporative fluid coolingapparatus 12(2) is the same as described earlier with reference to theevaporative fluid cooling apparatus 12(1), except in this exampleseparate top coils, a center divider and separate exhaust fans allow formore precise control over the cooling operation. As a result, thisadvantageously provides substantial water savings as it will requireless water to achieve the same cooling, as well as reasonable other costsavings.

Referring to FIG. 6 an example of another evaporative fluid coolingapparatus 12(3) is illustrated. The evaporative fluid cooling apparatus12(3) is the same in structure and operation as the evaporative fluidcooling apparatuses 12(1) and 12(2), except as illustrated and describedherein. Elements in the evaporative fluid cooling apparatus 12(3) whichare like those in evaporative fluid cooling apparatuses 12(1) and 12(2)have like reference numerals.

In this example, the housing 14 in the evaporative fluid coolingapparatus 12(3) includes a moveable barrier 100 which may be adjustablypositioned in the housing 14 to divide the cooling chamber 17 into twoseparate regions and which permit air flow between the air input 23 andthe air output 25, although the cooling chamber 17 can be divided inother manners and other proportions. The fluid coil 16(1) in theevaporative fluid cooling apparatus 12(3) comprises two separate fluidcoils 16(1 a) and 16(1 b) which are coupled in series with each of thefluid 16(1 a) and 16(1 b) positioned to extend across at least a portionof one of the regions in the cooling chamber 17, although the fluid coil16(1) may comprises other numbers of fluid coils in otherconfigurations. The fluid coil 16(2) in the evaporative fluid coolingapparatus 12(3) comprises two separate fluid coils 16(2 a) and 16(2 b)which are coupled in series with each of the fluid 16(2 a) and 16(2 b)positioned to extend across at least a portion of one of the regions inthe cooling chamber 17, although the fluid coil 16(2) may comprisesother numbers of fluid coils in other configurations. In this example,the output from the fluid coil 16(1 b) is coupled to the input of fluidcoil (2 a) so that fluid coils 16(1 a), 16(1 b), 16(2 a), and 16(2 b)are coupled in series and in this example form a “Z” shape The airmovement device 22 comprises two separate air movement device 22(a) and22(b) which are each positioned adjacent the air output 25 in one of theregions in the cooling chamber 17, although the air movement device 22may comprises other numbers of air movement devices in otherconfigurations and locations. The two separate air movement device 22(a)and 22(b) may each be controlled separately by the evaporative coolercomputing device 60 based on at least one characteristic, such asoutside air temperature by way of example only, to generate a flow ofair through the cooling chamber 17 from the one or more air inputs 23through the cooling chamber 17 and out the air output 25, although theair movement devices 22(a) and 22(b) may each be controlled in othermanners. One of the controllable vents or louvers 26 is positioned inthe housing 14 to provide controlled access to one of the regions in thecooling chamber 17, although other types and/or numbers of controllablevents or louvres could be used. The sprayer apparatus 20 in theevaporative fluid cooling apparatus 12(2) may be controlled by theevaporative cooler computing device 60 based on at least onecharacteristic, such as outside air temperature by way of example only,to spray in only one of the regions in the cooling chamber 17 on theoutlet side to supply the cooled fluid back to heat exchanger device28(1) in the air handler apparatus 32(1), although the sprayer apparatus20 could be configured to spray in the regions in the cooling chamber 17in other manners and/or patterns.

As noted earlier, the operation of the evaporative fluid coolingapparatus 12(3) is the same as described earlier with reference to theevaporative fluid cooling apparatus 12(1), except in this exampleseparate top and bottom coils, a center divider and separate exhaustfans allow for even more precise control over the cooling operation thanin previous examples. In 12(3) the separation into two separate airflowsides allows warmer air to move on the left in the example (the rightside top fluid coil 16(1 b) feeds fluid to the left side bottom fluidcoil 16(2 a) so the warmer top and bottom fluid coils 16(1 a) and 16(2a) are on the left, cooler fluid coils 16(1 b) and 16(2 b) on the right,creating a “Z” type arrangement of fluid movement) and cooler air on theright, at air flow generated by air movement devices 22(a) and 22(b) andsprayer rates provided by the sprayer apparatus 20 which are eachindividually managed and controlled by the evaporative cooler managementcomputing device 60 to maximize efficiency, allowing very precisecontrol over the operation of the tower. As a result, thisadvantageously provides even greater water savings with evaporativefluid cooling apparatus 12(3) than with evaporative fluid coolingapparatus 12(2) by way of example, providing substantial water savingsover standard designs, while further reducing other costs, all insavings should well exceed 5% over the evaporative fluid coolingapparatus 12(3) in many environments.

Referring to FIG. 7, another example of air handler apparatus 32(2) isillustrated. In this example, the air handler apparatus 32(2) could becoupled in and replace the air handler apparatus 32(1) in theenvironment 10 shown in FIG. 1 and would operate in the same manner asthe air handler apparatus 32(1) except as otherwise illustrated ordescribed herein, although the air handler apparatus 32(2) may be usedin other types of applications with other types of systems.Additionally, in this example the air handler apparatus 32(2) includes aplurality of heat exchanger devices 28(2)-28(4) each with a coolingfluid region 80 separated from a temperature transfer fluid region 82,an evaporator device 84 comprising an evaporator housing 86 and aplurality of evaporator coils 88(1)-88(3), reserve temperature transferfluid tanks 95(1)-95(3), and pump 90(1)-90(3), although the air handlerapparatus 32(2) could include other types and/or numbers of othersystems, devices, components and/or other elements in otherconfigurations.

The plurality of the heat exchanger devices 28(2)-28(4) each have one ofthe cooling fluid regions 80 which are configured to be coupled inseries between a fluid supply return from and a fluid supply to theevaporative fluid cooling apparatus 12(1), although other types and/ornumbers of heat exchanger devices in other configurations can be used.Each of the heat exchangers 28(2)-28(4) also has one of the temperaturetransfer fluid regions 82 which is separated from a corresponding one ofthe cooling fluid regions 80 and each is coupled to one of theevaporator coils 88(1)-88(3) as described in greater detail in theexample below.

The evaporator device 84 includes the evaporator housing 86 whichdefines an air passage having an air input 92 and an air output 94,although the housing could define other types of passages and have otherinputs and/or outputs. Additionally, the evaporator device 84 includesthe plurality of evaporator coils 88(1)-88(3) which are arranged inseries inside and along the evaporator housing 86 between the air input92 and the air output 94, although other types and/or numbers ofevaporator coils in other configurations may be used. Each of theplurality of evaporative coils 88(1)-88(3) has an output coupled to aninput to one of the temperature transfer fluid regions 82 in one of theheat exchanger devices 28(2)-28(4) and an input coupled to an outputfrom one of the temperature transfer fluid regions 82 in one of the heatexchanger devices 28(2)-28(4), although other configurations may beused.

In this particular example, one of the plurality of the heat exchangerdevices 28(2) that has a cooling fluid input configured to be coupled toa cooling fluid return from the evaporative fluid cooling apparatus12(1) is coupled to the one of the plurality of the evaporator coils88(3) closest to the air output 94, although other coupling arrangementsmay be used. Additionally in this particular example, another one of theplurality of the heat exchanger devices 28(4) that has a cooling fluidoutput configured to be coupled to a cooling fluid supply to theevaporative fluid cooling apparatus 12(1) is coupled to the one of theplurality of the evaporator coils 88(1) closest to the air input,although other coupling arrangements may be used. Further in thisparticular example, one of the plurality of the heat exchanger devices28(3) is coupled to an evaporator coil 88(2) comprising two evaporatorcoils 88(2 a) and 88(2 b) in a split counter flow design, although othertypes and/or numbers of evaporator coils could be used for evaporatorcoil 88(2), such as a single evaporator coil 88(1) or 88(3) by way ofexample only.

In this particular example, an output from the temperature transferfluid region 82 in heat exchanger device 28(2) is split to an inputlocated at the outermost portion or edges of each of the evaporatorcoils 88(2 a) and 88(2 b) (i.e. the outermost portions or edges of theevaporator coils 88(2 a) and 88(2 b) facing the air input 92 and airoutput 94, respectively) and an input back to the temperature transferfluid region 82 is coupled to an innermost portion of each of theevaporator coils 88(2 a) and 88(2 b), (i.e. between or in this examplenear the center of the evaporator coils 88(2 a) and 88(2 b)), althoughthe evaporator coils 88(2 a) and 88(2 b) can be coupled in othermanners. With this split counter flow design, the temperature transferfluid from the temperature transfer fluid region 82 of the heatexchanger devices 28(2) enters the outermost edges or portions of theevaporator coils 88(2 a) and 88(2 b) and flows into the middle where theevaporator coils 88(2 a) and 88(2 b) are joined thus creating a counterflow situation. Accordingly, with this counter flow design or inversecoupling this technology is able to more efficiently and effectivelyheat or cool the air passing through the evaporator housing 86. In thisexample the evaporator coil 88(2 a) may comprise a plurality of firstcoil sections 89(1 a)-89-4 a) coupled in series in one of the regionsand evaporator coil 88(2 b) may comprise a plurality of first coilsections 89(1 b)-89-4 b) coupled in series in one of the regions. Eachof the evaporator coils 88(1) and/or 88(3) may also be replaced by twoor more coils, such as with evaporator coils 88(2 a) and 88(2 b) in acounter flow design by way of example only. Further, the pipes used totransfer the temperature transfer fluid from the temperature transferfluid region 82 of the heat exchanger devices 28(2) has anelectronically controlled valve 97 as does the piping which transfersthe input back to the temperature transfer fluid region 82 also has anelectronically controlled valve 97. These valves may be used to vary theflow of the temperature transfer fluid to each section of the evaporatorcoils 88(2 a) and 88(2 b), or even close off one or the other coil incase of a leak or for other reasons

Each of pumps 90(1)-90(3) is coupled to pump temperature transfer fluidbetween one of the temperature transfer fluid regions 82 in the heatexchanger devices 28(2)-28(4) and one of the evaporator coils88(1)-88(3) when activated, although each of the pumps 90(1)-90(3) maybe coupled in other manners and locations. In this particular example,pump 90(2) coupled to the output from the temperature transfer fluidregion 82 in heat exchanger device 28(3) before the split to theoutermost portion or edge of each of the evaporator coils 88(2 a) and88(2 b). Additionally, each of the pumps 90(1)-90(3) may be coupled toone or more of optional reserve temperature transfer fluid tanks95(1)-95(3) from which additional temperature transfer fluid can beobtained or stored as needed. Further, each of the pumps 90(1)-90(3) maybe coupled to and controlled by the evaporative cooler managementcomputing device 60, although each may be controlled by other types ofdevices and/or in other manners, such as by manual engagement. Thetemperature transfer fluid in each of the temperature transfer fluidregions 82 in the heat exchanger devices 28(2)-28(4) may have a singleor blended transfer fluid with different boiling points to enable moreefficient and effective heating or cooling of the air.

An evaporator air movement device 96 may be positioned to provide a flowof the air from the air input 92 through the evaporator housing 86 andout the air output 94 when activated, although other manners forgenerating air flow may be used. In this particular example, theevaporator air movement device 96 may be coupled to and controlled bythe evaporative cooler management computing device 60, although theevaporator air movement device 96 may be controlled by other types ofdevices and/or in other manners, such as by manual engagement. Further,an damping or controlling device may be positioned at the fresh airinput 92 to control the amount of air moving across evaporator coilprior to be blended with the air input for returning air from thebuilding as way of example 99 where the fresh air input 92 will blendwith the return air input 99 prior to entering the evaporator coils 88(2a) and 88(2 b).

The operation of the air handler apparatus 32(2) is the same as theoperation of the air handler apparatus 32(1), except as illustrated anddescribed herein. In this particular example, the heat exchanger devices28(2)-28(4) in the air handler apparatus 32(2) each use a coolant orrefrigerant fluid with a different boiling point than the others,although again other arrangements can be used. The air handler apparatus32(2) may also have the refrigerant system 30 in the return air flowfrom the heat source 40 as shown in FIG. 1, although the air handlerapparatus may have other types and/or numbers of other systems, devices,components and/or other elements in other configurations. As displayedin FIG. 7 air handler apparatus 32(2) may comprises multiple evaporatorcoils 88(1)-88(3) with both single flow, e.g. evaporator coils 88(1) and88(3), and split counter flow, e.g. evaporator coils 88(2 a)-88(2 b)each with temperature transfer fluid designed to provide the mostefficient preparation of air for use in a building or other destination,although again other types and/or numbers of coils in otherconfigurations may be used.

In this particular example, fresh air may be introduced by the airmovement device 96 when activated into the air input 92 in theevaporator housing 86 to fresh air to the first evaporator coil 88(1) inthe air handler apparatus 32(2), although air or other fluids may beprovided in other manners. By utilizing a fresh air intake, the airhandler apparatus 32(2) helps to eliminate sick building syndrome (i.e.stale recirculating air in which fresh air is not introduced). The firstevaporator coil 88(1) operates as a cooling coil (evaporator) foroutside air in warm weather and also as a warming coil (condenser) towarm the cold fresh outside air without the use of energy from apre-heat coil as in prior art.

Next, the fresh air mixes with the return air 99 and passes evaporatorcoils 88(2 a)-88(2 b) which in this particular example form a dualmicrochannel counter flow coil, although other coil designs could beused. This example of the evaporator coils 88(2 a)-88(2 b) allows theoutside edge of coil 88(2 a) which is closest to evaporator coil 88(1)to flood with temperature transfer fluid from the temperature transferfluid region 82 of the heat exchanger devices 28(2) removing as muchenergy from the mixed air as it can. Next, as the ability of thetemperature transfer fluid to absorb additional energy is reduced orlost the mixed air continues to pass into the forward edge of evaporatorcoil 88(2 b), i.e. the edge or portion closest to evaporator coil 88(2a), where additional energy is absorbed cooling the mixed air prior topassing onto evaporator coil 88(3). The flooding of evaporator coil 88(2b) in the trailing edge, closest to evaporator coil 88(3) allows formaximum temperature transfer fluid contact time as the air leaves theevaporator coil 88(2 b) to ensure maximum energy transfer has occurred.This counter flow arrangement allows for a doubling of the effectivesurface of this dual microchannel counter flow coil formed by evaporatorcoils 88(2 a)-88(2 b) thus overcoming the inherent limitations of thestandard coil designs and allowing for maximum efficiency in thethinnest evaporator coil possible. This efficiency is further enhancedwhen a blended temperature transfer fluid is employed to allow forstaging of energy absorption within the two evaporator coils 88(2 a) and88(2 b), while returning the temperature transfer fluid reduces thecomponents necessary to achieve this efficiency.

Next, the mixed air passes evaporator coil 88(3) before exiting the airoutput 94 which is coupled to the building or other destination for thetreated air. Evaporator coil 88(3) receives the mixed air prior to itsoutput 94 from the unit 32(2) to ensure the proper temperature has beenachieved, thus the lowest energy air (coolest) of the evaporative coilsthus should be required to do the least work, hence the counter flow ofthe air from input 92 to output 94 is opposite to the flow of cooledfluid from the heat rejection tower, allowing the coolest water from thetower output 16(2) to receive the heat from the coolest evaporator coil88(3), then proceed to flow and absorb the heat energy from the firstmixed air evaporator coil 88(2) and then this warmed fluid is availableto either transfer the energy absorbed by the heat exchangers 28(2) and28(3) into the temperature transfer fluid via heat exchanger 28(4) toevaporator coil 88(1) which will transfer that heat energy to cold freshair acting as a condenser, warming it rather than employing a pre heatcoil as in prior art, or evaporator coil 88(1) will absorb heat energyfrom the warm fresh air and transfer that energy through the temperaturetransfer fluid to heat exchanger 28(4) and further warm the fluidreturning to the input of the tower 16(1) for heat rejection to theatmosphere. In cold weather this arrangement may employ all the heatenergy absorbed via heat exchangers 28(2) and 28(3) to warm the freshair through evaporative coil 88(1) thus removing any requirement for anyheat rejection, achieving maximum efficiency since no heat energy iswasted.

Accordingly, this example of the air handler apparatus 32(2) should besubstantially more efficient than the prior art due to the use ofthinner refrigerant evaporator coils 88(1)-88(3) rather than the thickchilled water and pre heat coils employed with prior technologies. Thismore efficient design will also reduce the energy required by the airmovement device 96 up to 30% to pull the air across the evaporator coils88(1)-88(3) and reduce the energy needed to cool that air movementdevice 96 as well. Further, this example of the design prevents the riskof evaporator coil 88(1) freezing since this coil is refrigerant basedand cannot freeze, further reducing the need for electrical heat tooperate the air handler apparatus 32.

Accordingly, as illustrated and described by way of reference to theexamples herein, this technology provides more effective and efficientair handler apparatuses for evaporative fluid cooling and methods. Inparticular, this technology provides air handler apparatuses which areable to assist evaporative fluid cooling apparatuses achieve a highdelta T and a low flow rate, i.e. gallons per minute (GPM), that areable to easily avoid low delta syndrome. By way of example, thistechnology can provide a high delta T of between twenty degrees toforty-five degrees and also a low flow rate or gallons per minute.Additionally, with this high delta T and a low flow rate design, thistechnology is able to provide a significant reduction, i.e. often inexcess of 50%, in the size and cost of piping and other parts whencompared against prior cooling systems. Further, with this high delta Tand a low flow rate design, this technology is able to output pure,non-saturated air and is able to utilize sprayer water that is chemicalfree. This technology also allows for a unique phased in integration ofthe compressor chiller that allow that compression chiller to operate ata greatly reduced lift compared to prior designs thereby lowering kW/tonrelationship.

Having thus described the basic concept of this technology, it will berather apparent to those skilled in the art that the foregoing detaileddisclosure is intended to be presented by way of example only, and isnot limiting. Various alterations, improvements, and modifications willoccur and are intended to those skilled in the art, though not expresslystated herein. These alterations, improvements, and modifications areintended to be suggested hereby, and are within the spirit and scope ofthis technology. Additionally, the recited order of processing elementsor sequences, or the use of numbers, letters, or other designationstherefore, is not intended to limit the claimed processes to any orderexcept as may be specified in the claims. Accordingly, this technologyis limited only by the following claims and equivalents thereto.

What is claimed is:
 1. An air handler apparatus comprising: a pluralityof heat exchanger devices coupled in series; a plurality of evaporatordevices coupled in series; a fluid transfer system coupled to transfertemperature transfer fluid between the heat exchanger devices and theevaporator devices when activated; wherein a first one of the pluralityof the heat exchanger devices coupled in series has a cooling fluidinput configured to be coupled to a cooling fluid return from anevaporative fluid cooling apparatus is coupled to a last one of theplurality of the evaporator devices coupled in series that is closest toan air output; and wherein a last one of the plurality of the heatexchanger devices coupled in series has a cooling fluid outputconfigured to be coupled to a cooling fluid supply to the evaporativefluid cooling apparatus is coupled to a first one of the plurality ofthe evaporator devices coupled in series that is closest to the airinput.
 2. A method for making an air handler apparatus, the methodcomprising: coupling a plurality of heat exchanger devices in series;coupling a plurality of evaporator devices in series; coupling a fluidtransfer system coupled to transfer temperature transfer fluid betweenthe heat exchanger devices and the evaporator devices when activated;wherein a first one of the plurality of the heat exchanger devicescoupled in series has a cooling fluid input configured to be coupled toa cooling fluid return from an evaporative fluid cooling apparatus iscoupled to a last one of the plurality of the evaporator devices coupledin series that is closest to an air output; and wherein a last one ofthe plurality of the heat exchanger devices coupled in series has acooling fluid output configured to be coupled to a cooling fluid supplyto the evaporative fluid cooling apparatus is coupled to a first one ofthe plurality of the evaporator devices coupled in series that isclosest to the air input.
 3. The apparatus as set forth in claim 1wherein at least one of the evaporative devices comprises: an evaporatorhousing comprising at least two adjacent regions; an evaporator coilcomprising at least two coils; one of the at least two coils comprisinga plurality of first coil sections coupled in series in one of theregions, with an input to a first one of the plurality of first coilsections adjacent an outer edge of the one of the regions in theevaporator housing, an output from a last one of the plurality of firstcoil sections located in an interior portion of the evaporator housing;and another one of the at least two coils comprising a plurality ofsecond coil sections coupled in series in another one of the regions,with an input to a first one of the plurality of second coil sectionsadjacent an outer edge of the one of the regions in the evaporatorhousing, an output from a last one of the plurality of second coilsections located in the interior portion of the evaporator housing. 4.The method as set forth in claim 2 wherein at least one of the pluralityof evaporative devices further comprises: providing an evaporatorhousing comprising at least two adjacent regions and an evaporator coilcomprising at least two coils; coupling one of a plurality of first coilsections for one of the at least two coils in series in one of theregions, with an input to a first one of the plurality of first coilsections adjacent an outer edge of the one of the regions in theevaporator housing, an output from a last one of the plurality of firstcoil sections located in an interior portion of the evaporator housing;and coupling another one of a plurality of second coil sections foranother one of the at least two coils in series in one of the regions,with an input to a first one of the plurality of second coil sectionsadjacent an outer edge of the one of the regions in the evaporatorhousing, an output from a last one of the plurality of second coilsections located in the interior portion of the evaporator housing.